Process of producing metals from metal oxides



United States Patent 01 3,156,557 PROCESS F PRODUCING METALS FROM .METAL 0XlDE Erik Dal-hi and igrnund Girstad, Vagshygd, near Kristi- 3,156,553 Patented Nov. 10, 1964 ice the temperature approaches the point (above about 400 C.) where the cement begins to lose its binding power, the particular coal that we employ will begin to coke and form a lattice of considerable strength. As a result ansand, and Hans Skretting, Kristiansand, Norway, instead of the pellets weakening as they are heated the assiggors tgolsfirllelrn'oiremislr A/S, Oslo, Norway, a corstrength of the pellets increases at higher temperatures porn on o orway o r N0 Claims priority, application Norway Oct. 4, 1960 nesigwfigm D720 43T d d y Claims (CL a an are reporte in arbitrary 10 numbers under such test ranging from 1 to 10. This 1s Thi i v nti r l t to a method of making preknown as the swelling index. For the purpose of our formed aggregates of considerable strength from ore invention We find that We Should use a Coal having 21 bodies and carbonaceous binders. These aggregates are el i g index of above 4 and preferably an index of the type used in the production of metals or carbides. 8 0r g C0611 With a normal Swelling indeX 0f Generally speaking the invention is used with ore bodies d by itself only just gives the minimum strength rethat can be reduced with carbon and particularly ore q ir However, the addition of about /2% to about bodies containing iron oxide with or without alloying in- 2% of pitch has the effect of raising the swelling index gredients such as manganese or chrome, and calcium comand by adding such pitch we may use coals which by pounds d i making l i bid themselves have a swelling index as low as about 3. t i know in the rt to make h ag gat om- 20. However, it is desired that the bituminous compound (by prising the ore together with the carbonaceous reducing W i h We mean the coal and the pitch if any is used) agent d a fl Thi for of aggregate i very fav should have a swelling index of at least 7 and preferable for dry reduction in the solid phase. When we ably 8 or higher. refer to aggregates we include briquettes or extruded In carrying out the invention the finely ground ore pieces but more generally the aggregates are in the form s mixed with separately ground coal. If pitch is inof pellets or small balls made by mixing the ingredi t cluded that should be ground with the coal. The amount with water and rolling them in a drum o n in lin d of coal will be adjusted to give the desired carbon for plates or saucers. The crude pellets thus obtained initiale r duction reaction and the fact that the coal also ly are not very strong having a point pressure strength serves to form a coke binder does not demand a change of about 3 to 5 kg. and a drop strength range from about in the usual carbon requirements. The combination of 50 em. up to about 150 cm. The term drop strength the ore and bituminous material is mixed with from 3 means the height in cm. from which a number of pellets to 10% of a water-activatable hydraulic binder such can be dropped onto a steel plate without more than as Portland cement, a cement rich in Al-oxide, or a half of them being broken. It aggregates are formed of cement produced on a base of granulated blast furnace simple iron ore fines considerable strength can be obslag. Usually about 5% of the hydraulic binder is about tained by sintering the aggregates at a temperature from right. The ore, coal and binder are preferably mixed, 1200-1300 C. but if carbon is included such sintering ried and then as usual water is added during the pelletin air or other oxidizing atmospheres causes considerizing. Ordinarily it will be sufiicient to have present in able loss of carbon and this is a substantial factor in the neighborhood of about 10% total moisture. cfimplltiflg 111600511 0f the Opafafion- The crude pellets thus formed should have an initial T add of Cement 101116 aggregates giVfiS an point pressure strength of at least about 3 kg. and after Proved Strength aflfif Storage for few y and the storing for a few days and hardening this should reach pellets are adequately strong at lower temperature ranges. 5 kg. and f bl 20 kg If Such n s are then However when 9 Pellets are used and heated the heated to about 709 C. in a neutral atmosphere it will cgmem tends dlsmtegrate and lose Strength owhgn the be found that instead of their strength falling oii as is tempraltum Pallets goes above .about 406 usual with cement hardened pellets such strength will This invention 18 based upon our discovery that aggren tes can be formed by combining the finely ground grea i ga This invention is illustrated in the following table m ore with powdered coal of very particular coking qualh fi f 1 h th f g f ities and then forming the aggregates with a hydraulic t e j exam? es 5 CW 6 a mg o Cement In such Case the aggregates n harden in a strength on heating when one uses the usual coal with a few days to give them adequate strength for storage and low $We n111g The example Shows a shipment, Subsequently whe th aggregates are d stantial increase in strength and the last three examples in a preheating or prereduction operation we find that as ar eXCfilleIlt- Portland Pressure Reducing Agent Cement, Pitch Swelling Strength (point Crude Stored Hardened percent Index kg. load) Drop Pellets 3Days 700 0. Height, cm.

Methil washed singles 5 0 1 Pressure droP---{ &8 3 8 1;? Do 5 1 1 it? ist 7% Pocahontas coal 5 0 5 3% Do 5 1 it; 253 it}, Belgian coal 5 O 8 undo "l Longyeai' coal 5 0 2% i3? It appears from the table that coal with a swelling index of 1 gives poor strength both after storing and hardening at 700 C. Even with addition of pitch the requirements for proper quality are not satisfied.

Coal with a swelling index 4.5 gives considerably better strength but only just up to that required. By addition of pitch, whereby the swelling index is increased from 4.5 to 7, a very satisfactory strength is obtained. Coal with a swelling index of 8 and 8.5 will give a good strength in the pellets without addition of pitch.

Charge pellets produced according to the invention can after a few days storage be smelted directly in a blast furnace, low shaft furnace or electric furnace without any special sintering operation. As mentioned above our charge pellets are especially suited for preheating and prereduction in the temperature range of 700-1000 C. with subsequent transfer of the hot charge to an electric furnace without intentional cooling. In the electric furnace the reduction is completed and also the smelting of the reaction products under formation of metal and slag.

In a preferred form of our process magnetic concentrate from the Syd-Veranger mine was ground so that at least 50% passed through a 200 mesh Taylor screen and this was mixed with finely ground Longyear coal from Spitzbergen (at least 50% through a 200 mesh Taylor screen) in a proportion corresponding to approximately 175 parts fixed carbon per 950 parts Fe. These finely ground ingredients were mixed with Portland cement in the dry state in a concrete mixer and then pelletized on a saucer type pelletizer of about 1.5 m. in diameter on which the charge was sprayed with suificient water to bring its moisture up to about 10%. The pellets were produced at the rate of approximately 100 kg. per hour and had a diameter from 10 to 25 mm. These pellets had the strength indicated in the last line of the above table.

It is to be understood that the strength value after heating is given to show that they would not disinte rate during use but actually the pellets were used after a few days storage without any special sintering step as the heating took place during normal use.

Charge pellets made in accordance with this invention can be treated in one or more shafts placed directly above the furnace or in a rotary kiln from which the hot charge is transferred to the smelting furnace by means of insulated containers. The use of charge pellets for electric furnaces presents great advantages compared with the conventional process where ore, sinter, fluxes and coke are smelted. Charge pellets contain the main constituents of the charge, ore and coal, the latter being transformed to coke in the usual operation of a prereduction furnace. The cement which is added will wholely or partly cover the demand for fluxes. In many cases it will be economical to use Portland cement as a binding agent as the charge will thereby receive an excess of lime. With some iron ores poor in A1 0 it is, however, an advantage to use Al-cement for at the same time to add Al-oxide to the charge. The invention therefore also has the advantage that the binding agents used take their natural part in the process as fluxing and reducing agents.

It is to be understood that the examples given are indicated only by way of illustration to show our preformed method of carrying out the invention and that the same may be modified in many particulars.

What is claimed is:

1. The process of producing charge pellets characterized by the fact of having a point pressure strength initially of at least 3 kg. and, upon three days storage, of at least kg., and further characterized by the fact that upon heating of the pellets to 700 C. the point pressure strength thereof increases substantially, which comprises the steps of mixing together finely divided charge material which can be reduced with carbon and which is selected from the group consisting essentially of iron oxide, iron oxide combined with alloying ingredients and calcium compounds, with a finely divided bituminous binding agent having an effective swelling index of at least 4.5 and comprising in major part finely-divided coal, mixing into the mixture so formed from about 3% to about 10% by weight of a water-activatable hydraulic cement and then pelletizing the final mixture with the aid of water.

2. A process in accordance with claim 1 in which the bituminous binding agent comprises an admixture of finely divided crude coal having a swelling index of about 3 to less than 4.5 and from 0.5 to 2% pitch, the admixture having an effective swelling index of at least 4.5

3. A process in accordance with claim 1 in which about 10% of water is added to the final mixture during pelletization thereof.

4. A process in accordance with claim 1 in which the bituminous binding agent comprises crude coal having a swelling index of at least 8.

5. A charge pellet characterized by the fact of having a point pressure strength initially of at least 3 kg. and,

upon three days storage of at least 15 kg, and further characterized by the fact that upon heating of the pellets to 700 C. the point pressure strength thereof increases substantially, which comprises a pelletizcd admixture of finely divided charge material which can be reduced with carbon and which is selected from the group consisting essentially of iron oxide, iron oxide combined with alloying ingredients and calcium compounds, finely divided bituminous binding agent having an effective swelling index of at least 4.5 and comprising in major part finelydivided coal and from about 3% to about 10% by Weight of a water-activatable hydraulic cement.

6. A pellet in accordance with claim 5 in which the bituminous binding agent comprises an admixture of crude coal having a swelling index from about 3 to less than 4.5 and from about 0.5 to about 2% of pitch, said admixture having an effective swelling index of at least 4.5.

7. A pellet in accordance with claim 5 which includes about 10% of water.

8. A pellet in accordance with claim 5 in which the water-activatable hydraulic cement contains a substantial amount of aluminum oxide.

9. A process in accordance with claim 1 in which the amount of said bituminous binding agent is suificient to supply the carbon required for reducing said charge material.

10. A pellet in accordance with claim 5 in which the amount of said bituminous binding agent is sufiicient to supply the carbon required for reducing said charge material.

References Cited in the tile of this patent UNITED STATES PATENTS 833,005 Steinberg Oct. 9, 1906 1,334,331 Vogel Mar. 23, 1920 1,896,088 Kern Feb. 7, 1933 2,405,278 Vance Aug. 6, 1946 2,808,325 Subervie Oct. 1, 1957 2,918,364 Lesher Dec. 22, 1959 FOREIGN PATENTS 3,314 Great Britain 1876 265 Great Britain 1877 

1. THE PROCESS OF PRODUCING CHARGE PELLETS CHARACTERIZED BY THE FACT OF HAVING A POINT PRESSURE STRENGTH INITIALLY OF AT LEAST 3 KG. AND, UPON THREE DAYS'' STORAGE, OF AT LEAST 15 KG., AND FURTHER CHARACTERIZED BY THE FACT THAT UPON HEATING OF THE PELLETS TO 700*C. THE POINT PRESSURE STRENGTH THEREOF INCREASES SUBSTANTIALLY, WHICH COMPRISES THE STEPS OF MIXING TOGETHER FINELY DIVIDED CHARGE MATE RIAL WHICH CAN BE REDUCED WITH CARBON AND WHICH IS SELECTED FROM THE GROUP CONSISTING ESSENTIALLY OF IRON OXIDE, IRON OXIDE COMBINED WITH ALLOYING INGREDIENTS AND CALCIUM COMPOUNDS, WITH A FINELY DIVIDED BITUMINOUS BINDING AGENT HAVING ANEFFECTIVE SWELLING INDEX OF AT LEAST 4.5 AND COMPRISING IN MAJOR PART FINELY-DIVIDED COAL, MIXING INTO THE MIXTURE SO FORMED FROM ABOUT 3% TO ABOUT 10% BY WEIGHT OF A WATER-ACTIVATA BLE HYDRAULIC CEMENT AND THEN PELLETIZING THE FINAL MIXTURE WITH THE AID OF WATER. 